Concealed controlled air vent system, method and apparatus

ABSTRACT

A controlled vent assembly is provided, which may be extended to support various duct sizes using a combination of a base unit and two types of extensions, and crutches. The extensions may provide additional functions or capacities in addition to size adjustment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims priority on U.S. Provisional Application No. 62/103,124, now pending, filed on Jan. 14, 2015, which is herein incorporated by reference.

FIELD

The subject matter of the present disclosure relates to a system, method and apparatus for controlling air flow in either a supply or return air vent within a residential or commercial building.

BACKGROUND

Many existing and future homes and small businesses have heating, ventilation and cooling (HVAC) systems that are based on one or more air blowers connected to supply air and return air ducts. The system is typically controlled through the use of zone type system whereby more or less conditioned air by volume is delivered through restricted static dampers and/or manually controlled vent covers. Dampers within the ductwork typically allow the system to balance the air at vents to compensate for more restrictive ducts and or longer ducts. The end of the duct is typically terminated with a vent cover or a register which in many cases has a mechanical means to restrict airflow. The use of static dampers and manually controlled covers or registers may be problematic as even though a system may be optimised for a given situation, seasonal differences along with modal differences such as heating versus cooling may require continual adjustment to the airflow. Automatic zone systems solve these issues and are capable of adapting the airflow in an optimal manner with respect to comfort.

Placing automatically controlled dampers in existing ductwork may not be economically viable due to building construction issues that leave the ductwork concealed as is the case with many basements that have been finished off with wall or ceiling panels.

A number of methods for zone control have been developed. Alles (U.S. Pat. No. 6,983,889 issued on Jan. 10, 2006) proposes the use of air bladders placed in ductwork to regulate the air flow to different zones and control the temperature. A solution proposed by Kath (U.S. Pat. No. 5,927,599 issued on Jul. 27, 1999) also requires a special control unit to be installed in the existing ductwork to regulate air flow. These types of installations, requiring access or modifications to the ducts, are expensive to retro-fit.

Brinkerhoff et al. (U.S. Pat. No. 6,692,349 issued on Feb. 17, 2004) and Carter (U.S. Pat. No. 8,142,265 issued on Mar. 27, 2012) describe different forms of electrically controlled motor driven vents that can be used to replace manually controlled mechanical vents. Fisher (U.S. Pat. No. 7,130,720 issued on Oct. 31, 2006), Zou et al. (U.S. Pat. No. 7,832,465 issued on Nov. 16, 2010) and Kates (U.S. Pat. No. 8,020,777 issued on Sep. 20, 2011) each describe different zone control systems in which motorized air vents are used to regulate the air flow to different zones, with each zone controlled by its own zone thermostat. When retrofitting a building, such systems do not require the existing ducts to be modified and use wireless links between the vents and zone thermostats to avoid the need to install additional wiring.

The new vents must be provided in different sizes to meet the market requirements where many standard and non-standard sizes have been adopted. This is problematic as the installer must first determine what sizes are required before the supplier can fulfill the requirement.

Another problem with replacing existing vent covers or registers is that the new automatic vent or register may not meet the aesthetic expectations when compared with the original vent cover. Likewise some homes have historically significant or very expensive registers custom made for unique decorative purposes.

It would thus be desirable to provide a controlled air vent system, which would at least partly address the disadvantages of the existing technologies.

SUMMARY

It would thus be desirable to be provided with a novel controlled air vent system.

The embodiments described herein provide in one aspect an HVAC diffuser adapted to various boot sizes, comprising a base unit, and at least a first extension module adapted to be mounted to the base unit for increasing a transversal dimension of the diffuser.

The embodiments described herein provide in another aspect a method of installing a diffuser to an HVAC boot, comprising:

-   -   a) providing a base unit;     -   b) providing at least one extension module;     -   c) mounting the extension module to the base unit for varying a         span thereof in accordance with a size of the boot; and     -   d) mounting the assembled base unit and extension module to the         boot.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings which show at least one exemplary embodiment, and in which:

FIG. 1A is an illustration shown in perspective of a vent assembly according to one of various exemplary embodiments;

FIG. 1B is an exploded view of the vent assembly of FIG. 1A with a duct and a register;

FIG. 1C is a fragmented view partly in cross section of the vent assembly, the duct and the register of FIG. 1B, shown in an assembled position;

FIG. 2A is an illustration shown in perspective of a crutch according to one of various exemplary embodiments;

FIG. 2B is a fragmented view partly in cross section of the vent assembly with the crutch of FIG. 2A applied as a suspension arm;

FIG. 3A is a perspective view of a base unit of the vent assembly according to one of various exemplary embodiments;

FIG. 3B is a block diagram of a control module according to one of various exemplary embodiments;

FIGS. 4A and 4B are respectively exploded and assembled perspective views of a length extension integrated with the base unit of FIG. 3A according to one of various exemplary embodiments;

FIGS. 5A to 5E are various perspective views of a width extension integrated with the base unit of FIG. 3A according to one of various exemplary embodiments; and

FIGS. 6A and 6B are perspective views of the length extension shown respectively in closed and open positions, according to one of various exemplary embodiments.

DESCRIPTION OF VARIOUS EMBODIMENTS

The system, method and apparatus disclosed herein provides means to mitigate some shortcomings of known devices by providing a single product that may be adjusted in all three dimensions, so that it works with various sizes of rectangular duct openings and allows for controlling airflow while still using the existing vent cover or floor register.

In one aspect, there is provided a single controlled vent assembly that can be adjusted in size to meet the needs of duct work openings of various sizes and shapes. To this end, the vent assembly provided by the invention comprises a base unit that may be extended using various modules, or extensions. The base unit and various extensions may be provided to the user separately (for instance in a kit form), to be put together for a particular duct size, or they may be provided pre-assembled, to be adopted to a particular duct size by removing extensions along the length or width of the assembly or both. This system, method and apparatus allows a single assembly to meet the needs of the market without prior knowledge of the specific duct vent size openings. Any width or length sections that are not required may be kept for future applications or disposed of.

in another aspect, there is provided a controlled vent assembly that may be concealed beneath or behind the existing register cover without modification to the ductwork or existing register cover. Placement of the controlled vent is flexible in that the concealed assembly may rest within the boot of the ductwork on its frame or on crutches provided with the assembly that may easily be removed. The crutches are provided with sufficient length and may simply be trimmed to meet the needs of the specific application. The crutches may also be re-orientated to become suspension arms for applications where the heel of the ductwork vent opening is too long. Additional connection points on both the base unit and extension modules allows the assembly to be affixed to the walls of the vent boot portion of the ductwork.

In a third aspect, the extensions comprise functional components that may integrate with the controlled vent assembly, thus providing an incremental function or capacity at the same time as they provide the dimensional adjustment to fit various ductwork.

Details will now be provided on various exemplary embodiments of the present system, method and apparatus.

Referring to FIG. 1A, a vent assembly 100 comprises a base unit 101, an optional width extension 102, an optional length extension 103, and four crutches 104. In this embodiment, the vent assembly 100 may have assembly width W and length L, so that it may fit into ductwork boot 99 as shown in FIGS. 1B and 1C, and control the air flow through a register 97.

Each of the four crutches 104, an embodiment of which is shown in FIG. 2A, comprises two tracks 1042 that may slide into matching grooves 1011 of any corner of the base unit 101 (see FIG. 3A), or into matching grooves 1021 of the width extension 102 if installed, or matching grooves 1031 of the length extension 103 if installed, as shown respectively in FIGS. 5A and 4A. When installed, the crutches 104 may slide along these grooves to allow the vent assembly 100 to adapt to ducts with boots at various depths.

The vent assembly 100 may rest directly within the boot 99, or may be supported by the crutches 104, which crutches may slide in either direction to match the depth of the boot 99. Furthermore, if the boot of the duct is too long, the crutches 104 can act as suspension arms by hanging them using the protruding lips 1043 from the upper edge of the boot 99 immediately beneath the register 97, as illustrated in FIG. 2B. Each crutch 104, as shown in FIG. 2A, also comprises a plurality of teeth 1044 that engage with a matching tooth on the wall of the base unit 101, or of the width extension 102 or of the length extension 103, and restricts the sliding motion of the crutch 104 and smart diffuser, which helps to keep the diffuser in position as installed by the user.

FIG. 3A shows an illustration of the base unit 101, wherein the Base unit 101 comprises a main frame 1014, housing a plurality of flaps 1012 and a control module 1013 that is adapted to actuate the flaps 1012, opening and closing them in order to allow or restrict air flow. The base unit 101 further includes connection points 1015 which may be used to secure the vent assembly 100 to either the duct itself or the pre-existing vent cover or air register using mechanical fasteners. The same connection points may be found on all extensions as well for the same purpose.

FIG. 3B shows a block diagram of the control module 1013 comprising a microprocessor 1013-7, a Memory 1013-9, a DC Power Manager Battery Bank 1013-12 and a Reset Switch 1013-14, which may be used to control other components including a motor control 1013-11 to drive a servo motor (not illustrated) used for actuating the flaps 1012. Furthermore, the control module 1013 comprises several sensors that may provide detection of harmful gases and measure various properties of the air flow sooner than they may detect or measure same if they were placed outside the ductwork. Such sensors may include a CO Sensor 1013-3 that may detect carbon monoxide, a temperature T Sensor 1013-4, and a humidity H-Sensor 1013-5. In addition, the control module 1013 herein comprises a Microphone 1013-6, LEDs 1013-8, a Speaker 1013-15, and a Wireless Transceiver 1013-13 to communicate with a user device. Environmental sensors for temperature and humidity may provide local or remote feedback to enable control of the airflow to meet comfort requirements. The microphone may be used to provide local or remote control of the airflow to minimise undesirable noise generated by the airflow due to fractional angular control of the actuating flaps at various differing air velocities.

With reference to FIG. 3A, in an embodiment, a width W and a length L′ of the base unit 101 are typically chosen to fit the smallest forced air duct boot that is available generally for home HVAC installations, and either dimension can be augmented independently or in combination in order to fit a range of duct sizes, that is by adding either width or length extensions, or both. Thus, as shown in FIGS. 4A and 4B, a length extension 103 may be added to the base unit 101 to achieve the same length L of the assembly shown in FIG. 1A, while maintaining the width W′. The length extension 103 comprises tracks 1032 that may slide into the grooves 1011 of the base unit 101, but also includes grooves 1031 that allow the tracks 1042 of the crutches 104 to slide therein to provide the depth support for the vent assembly 100, as mentioned hereinabove.

Likewise, as shown in FIG. 5A, the width extension 102 may be added to the same base unit 101 to achieve, for example, an assembly having a width W and a length L. The width extension 102 comprises a flap 1023 that may be connected to the flaps 1012 of the base unit 101 via a bridge 12 shown in FIG. 5B. The resulting flap assembly 10123, shown separately in FIG. 5C, may thus be installed in the vent assembly 100 and controlled by the servo motor of the control module 1013, as shown in FIG. 5D, thereby providing the same behaviour in the extension 102 as in the rest of the vent assembly 100.

The width extension 102 comprises tracks 1022 that may slide into the grooves 1011 of the base unit 101, and also includes grooves 1021 that allow the tracks 1042 of the crutches 104 to slide therein to provide the depth support for the vent assembly, thereby resulting in the complete vent assembly 100 shown in FIG. 5E, which supports a different duct size than the one supported by the base unit 101 or by another vent assembly having a different extension.

The various width and length extensions may be designed in accordance with the present teachings in order to support any ductwork with rectangular registers. For example, FIGS. 6A and 6B show the length extension 103 that may be added to the vent assembly 100 of FIG. 5E in order to obtain the vent assembly 100 of FIG. 1A. Furthermore, the length extension 103 of FIGS. 6A and 6B comprises a battery housing 1024, with a connector 1025, thereby allowing the length extension 103 to provide additional power to the vent assembly as well as providing support for a different duct size. Those of skill in the art may appreciate that the extension 103 may provide housing for devices other than batteries, with connector 1025 comprising data as well as power connectivity, for allowing the introduction of new functions not available in the control module 1013.

According to the present system, the various embodiments and configurations of the vent assembly 100 may thus support various duct sizes using a combination of the base unit 101 and the two extensions 102 and 103, in addition to the crutches 104. These extensions 102 and 103 may further provide additional functions that integrate with the base unit 101 using power and data connectors.

it is noted that the vent assembly 100 may be DC or AC line powered, and that it can be wired back to a central controller or another unit for control and communication purposes.

With the present system, a great deal of flexibility of the vent assembly is offered to the consumer

Finally, while the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the embodiments and non-limiting, and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the embodiments as defined in the claims appended hereto. 

1. An HVAC diffuser that supports various boot sizes, comprising: a base frame that has a rectangular cross section, wherein a first plurality of assembly features is disposed in a first configuration on the walls of said base frame, and a second plurality of assembly features is disposed in a second configuration on the walls of said base frame; at least one extension module having a third plurality and a fourth plurality of assembly features wherein at least one assembly feature of said third plurality mates with at least one feature of said first plurality to produce an assembled frame having a fifth plurality of assembly features with a configuration that is isomorphic to said first configuration and a sixth plurality of assembly features with a configuration that is isomorphic to said second configuration; a plurality of crutches, each having a seventh plurality of assembly features that engages with one of said first or fifth plurality of assembly features, and an eighth plurality of assembly features that engages with one of said second or sixth plurality of assembly features, such that said crutch may move orthogonally to the rectangular cross section of said base frame; a first assembly comprising a plurality of electrical components; and a second assembly comprising a plurality of louvers that may be selectively positioned to one of an open position and a closed position.
 2. The diffuser of claim 1, wherein said first plurality and third plurality of assembly features are comprised of mating tracks, and said second plurality and fourth plurality of assembly features are comprised of mating teeth.
 3. The diffuser of claim 1, wherein said base frame further comprises a lever for manually positioning said plurality of louvers.
 4. The diffuser of claim 1, wherein said electrical components include a gas sensor, temperature sensor, humidity sensor, stepper motor, servo motor, wireless transceiver, LEDs, and batteries.
 5. The diffuser of claim 1, wherein said plurality of louvers is coupled to one of a stepper motor and a servo motor of said first assembly.
 6. The diffuser of claim 1, further comprising wedge-shaped protrusions on the inside of said base frame along its length such that when said louvers are in a closed position they overlap said protrusions.
 7. The diffuser of claim 1, further comprising a plurality of screw mounts disposed at the top edge of said base frame and said extension module.
 8. A method of installing the diffuser of claim 1, comprising: a) sliding said extension module into at least one of said first plurality of assembly features; b) sliding each one of said plurality of crutches into at least one of said first plurality or said third plurality of assembly features; c) placing the smart diffuser into an HVAC boot; and d) adjusting the position of each of said first set of crutches to come in contact with the surface of said HVAC boot.
 9. An HVAC diffuser adapted to various boot sizes, comprising a base unit, and at least a first extension module adapted to be mounted to the base unit for increasing a transversal dimension of the diffuser.
 10. The diffuser of claim 9, wherein the first extension module is adapted to be mounted along a long side of the base unit for increasing a width of the diffuser.
 11. The diffuser of claim 9, wherein the first extension module is adapted to be mounted along a short side of the base unit for increasing a length of the diffuser.
 12. The diffuser of claim 10, wherein there is further provided a second extension module that is adapted to be mounted along a short side of the base unit for increasing a length of the diffuser.
 13. The diffuser of claim 9, wherein the base unit and any extension module mounted thereto form an assembly, and wherein a plurality of crutches are provided, each crutch being adapted to be mounted to a respective corner area of the assembly, the crutches allowing the assembly to be positioned in the boot behind a register.
 14. A method of installing a diffuser to an HVAC boot, comprising: a) providing a base unit; b) providing at least one extension module; c) mounting the extension module to the base unit for varying a span thereof in accordance with a size of the boot; and d) mounting the assembled base unit and extension module to the boot. 